Method of making a floor mat having a channel

ABSTRACT

The floor mat of the present process is a pliable multilayer structure having an upper face layer and a base layer. The base layer has a main body section bordered by an edge section. Preferably, the main body section is relatively thin and the edge section is relatively thick. A surface of the base layer is adapted to confront flooring overlaid by the mat. The edge section has a channel extending longitudinally thereof, and preferably opening from the bottom surface of the edge section. A portion of the main body section can have a channel molded therein such that a portion of the main body section is disposed above the remainder of the main body section to provide a decorative and aesthetically pleasing design in the main body section.

RELATED APPLICATION

This application is a Divisional of application Ser. No. 07/872,456,filed 23 Apr. 1992, now U.S. Pat. No. 5,362,544, which is aContinuation-in-Part of Ser. No. .[.027.]..Iadd.07/.Iaddend.694,966filed May 3, 1991 now U.S. Pat. No. 5,154,961 the disclosures of whichare incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates to floor mats such as those used in the passengercompartments of automobiles or as entry mat in homes or workplaces.

Floor mats of this type found in automobiles or homes generally are madeof a combination of an elastomeric material (e.g., rubber) and acarpeted material. Typically the carpeted material is attached to arubber backing layer by any of various methods. Unfortunately the layersof these mats tend to separate at the edges of the mat when the mat isin use.

Various methods have been used to provide additional strength to theattachment between layers of the mat to prevent the separation of themats layers at the edge. For example, methods include surging yarn overthe edges of the mat or a tape may be placed covering the edge of themat and then stitched to the mat. A disadvantage of these methods isthat the stitching holding the edging tape to the mat also tends to wearout with use and the tape separates from the mat. Furthermore, the tapeand stitching must be added to the mat after the mat has been molded,thereby adding an additional manufacturing step.

Another problem is that the mats have a tendency to move or shift due tothe action of feet on the mat. Various efforts have been made to preventslippage by use of permanent retention means such as hooks, snapfasteners, Velcro® strips and the like. However, none of these arecommercially successful because they tend to distract from theaesthetics of the mat. Another solution, particularly for mats used inautomobiles, is to use an array of downwardly extending projections or"nibs" to reduce slippage such as proposed, for example in commonlyassigned U.S. Pat. No. 4,174,991 to Reuben. An alternative solution isto use a tacky adhesive on the undersurface of the mat such as proposedin U.S. Pat. No. 4,609,850 to Rockett et al. A combination of nibs andtacky adhesive has also been proposed in commonly assigned U.S. Ser. No.07/642,926 filed Jan. 18, 1991, and a combination of nibs andpolyurethane foam has been proposed in commonly assigned U.S. Ser. No.07/687,234 filed Apr. 18, 1991.

It would be highly desirable to provide a floor mat which does not havethe need for edge stitching, taping, or the like while eliminating theslippage problems associated with conventional floor mats.

SUMMARY OF THE INVENTION

The floor mat of the present invention is a pliable multilayer structurehaving an upper face layer and a base layer adapted to confront flooringoverlaid by the mat. The base layer has a main body section bordered byan edge section. Preferably, the main body section is relatively thinand the edge section is relatively thick. The edge section has a channelextending longitudinally thereof, and preferably opening from the bottomsurface of the edge section. The edge section has an upper surfacedisposed at an elevation above the elevation of the main body section ofthe base layer. This upper surface preferably provides a decorative edgeportion in the face layer. The thicker edge section provides stiffnessto the periphery of the base layer and serves to reduce deformation ofthe channel of the mat during use. Additionally, the thicker sectionhelps prevent slippage of the mat. The channel of the floor matpreferably has a plurality of ribs disposed within and extendingtransversely across the channel to further stiffen the channel. Aportion of the main body section can also have a channel molded therein,and preferably opening from the bottom surface of the main body sectionof the base layer. This portion of the main body section is disposed atan elevation above the elevation of the remainder of the main bodysection. This raised portion provides a decorative and aestheticallypleasing design in the main body section.

The floor mat, and preferably does, include anchoring means to assist inpreventing slippage. For example, the floor mat can include a pluralityof nibs extending downward from the bottom surface of the base layer, anadhesive layer on the bottom surface of the base layer, a layer ofpolyurethane foam having a high coefficient of friction, or anycombination thereof.

The present invention further encompasses a method of producing a floormat having the above pliable multilayer structure. The method includescontacting the top surface of the base layer to the bottom surface ofthe upper face layer and placing the layers under a compressive moldingpressure applied to the bottom surface of the base layer and the topsurface of the base layer. A channel is molded in, and preferably opensfrom, the edge section of the base layer while the base layer and theupper face layer are under compressive molding pressure. A portion ofthe bottom surface of the face layer is embedded in the top surface ofthe upper face layer. The base layer is heated while it and the facelayer are under the compressive molding pressure to join the layerstogether and to cure the base layer.

DESCRIPTION OF THE DRAWINGS

Other features of the invention will be apparent from the followingdescription of illustrative embodiments thereof, which should be read inconjunction with the accompanying drawings, in which:

FIG. 1 is a top perspective view of a floor mat in accordance with theinvention;

FIG. 2 is a bottom perspective view of the mat;

FIG. 3 is an enlarged fragmentary sectional view taken substantiallyalong the line and in the direction of the arrows 3--3 of FIG. 1;

FIG. 4 is a perspective view of the mat illustrating the pliable natureof the mat;

FIG. 5 is a fragmentary bottom plan view of an alternative embodiment ofa floor mat in accordance with the present invention;

FIG. 6 is an enlarged fragmentary sectional view taken substantiallyalong the line and in the direction of the arrows 6--6 of FIG. 5;

FIG. 7 is a fragmentary bottom plan view of a floor mat in accordancewith the present invention; and

FIG. 8 is a fragmentary sectional view taken substantially along theline and in the direction of the arrows 8--8 of FIG. 7;

FIG. 9 is a fragmentary sectional view illustrating another embodimentof the invention;

FIG. 10 is a top perspective view of a household floor mat in accordancewith the invention;

FIG. 11 is a bottom perspective view of the floor mat shown in FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention can, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, applicant provides theseembodiments so that this disclosure will be thorough and complete, andwill fully convey the scope of the invention to those skilled in theart.

Referring now more particularly to the drawings, the pliable multilayerfloor mat of the present invention is indicated generally by the numeral10. The term "pliable" relates to the mat being easily folded or flexedand is illustrated in FIG. 4. For example, a floor mat held at arm'slength which is unable to support its own weight would be pliable or amat which can be rolled up would be pliable. The floor mat includes anupper face layer 12 overlying a base layer 15 the base layer 15 havingan upper surface 17 and a bottom surface 19. The bottom surface 19 isadapted to confront flooring overlaid by the mat. The base layer 15further includes a relatively thin main body section 20 bordered by arelatively thick edge section 21 as compared to each other. The edgesection 21 of the base layer 15 has a channel 22 extendinglongitudinally thereof, and preferably opens from the bottom surface 19of the base layer 15.

The upper face layer 12 preferably is formed from carpet material whichis wear-resistant and has a pleasing appearance. It will be apparent toone skilled in the art that the face layer can be an elastomer layer 12a(FIG. 9), a thermoplastic layer, such as a vinyl compound, or anon-woven layer. The carpet material may be tufted, woven, needlepunched or the like, and may be backed or unbacked. Preferably, thecarpet material is a tufted pile carpet construction, i.e., a pluralityof pile yarns extend through a primary backing to form loops which arecut to form tufts. The fibers of the pile yarns can be composed ofnatural or synthetic fibers and may be thermoplastic or thermosetting.The carpet fibers employed in the present invention are described inU.S. Pat. No. 4,174,991 to Reuben, the disclosure of which isincorporated herein by reference as if set out fully, and includepolyamide fibers such as nylon fibers, particularly nylon 6 and nylon66, polyester fibers, acrylic fibers, polypropylene and blends andcopolymers thereof.

The base layer 15 is preferably formed of a heat curable elastomericmaterial or a thermoplastic material. Exemplary heat curable elastomericmaterials include vulcanizable elastomers which are cured by a sulfurreaction mechanism or a metallic oxide mechanism. Particularly suitableelastomeric materials are rubbers such as natural rubber, butadienepolymers and copolymers such as styrene-butadiene rubbers andpolybutadiene rubbers, isoprene polymers and copolymers, chloroprenerubbers such as neoprene, nitrile rubbers, butyl rubbers, andethylene-propylene rubbers, and blends and copolymers thereof.Styrene-butadiene rubbers are particularly preferred for use in thepresent invention. Suitable thermoplastic materials include polyvinylchloride, polyethylene, ethylene vinyl acetate, polypropylene,polystyrene, and thermoplastic rubber.

As shown in FIGS. 1-3, the channel 22 circumscribes the periphery of thefloor mat 10. The upper surface 23 of edge section 21 is disposed at anelevation above the elevation of the main body section 20. Preferably,this elevated upper surface 23 of the base layer 15 provides adecorative and aesthetically pleasing edge portion 24 to the face layer12 of the floor mat 10, and eliminates the need for stitching or bindingof the edge of the mat. The elevated upper surface 23 of edge section 21reduces the tendency of the uppermost face layer 12 to separate from thebase layer 15. The decorative edge portion 24 of the face layer 12 ispreferably about 1/4 inches high, but heights from about 1/8 to about1/2 inches may be used.

As illustrated in FIG. 3, the channel 22 is formed in and preferablyopens from the bottom surface 19 of the base layer 15. Preferably, thechannel 22 assists in creating the thicker edge section 21 of the baselayer 15. As described below, a thicker edge section 21 of the floor matmay optionally result from the redistribution of base layer materialduring the molding, particularly compression molding of the floor mat.This thicker edge section 21 also prevents the mat 10 from slippingduring use.

The shape of the channel 22 is shown as substantially rectangular inFIGS. 1-8 and as a tapered channel in FIG. 9, but may be of other shapessuch as V-shaped or U-shaped or semicircular. The channel 20 ispreferably about 1/4 inches wide and about 1/4 inches deep, however,suitable dimensions for the channel are typically from about 1/8 toabout 1/2 inches wide and from about 1/8 to about 1/2 inches deep. Whenin use, the bottom surfaces of the main body portion 20 and the edgesection 21 of the base layer 15 are, as shown in FIGS. 3 and 6,substantially coplanar. The bottom surface 19 of the base layer 15 whichextends outward from the channel 22 to the edge of the floor mat 10 andthe bottom surface 15 of the base layer 15 which extends inward from thechannel 20 both are closely adjacent and preferably underlying surfaceof the flooring.

As shown in FIGS. 3, 6, 8, and 9 the present invention may optionallyhave a step portion 27 extending from the outer edge of the thicker edgesection 21 of the base layer 15. The width of the step portion 27 ispreferably less than one inch and more preferably greater than 1/16inch. The step portion 27 of the floor mat extends outward from the edgesection 21 to the edge of the floor mat 10, and during use the bottomsurface of the step portion 27 is substantially coplanar with theportion of the bottom surface 19 of the base layer 15. The step portion27 adds area for bonding of the face layer 12 to the base layer 15thereby increasing the strength of the bond between the layers andincreasing the resistance to separation. Furthermore, the step portion27 provides a smooth edge to the floor mat 10 without the use of bindingmaterials by allowing for the return from the edge section 21 of thebase layer 15 to the normal thickness of the base layer 15 and therebyexposing a limited portion of the base layer 15 to view.

In an alternative embodiment of the present invention, as shown in FIGS.5, 6 and 9, rib members 30 are disposed in and extend transverselyacross the channel 22, strengthen the channel 22 and prevent distortionof its shape. The rib members 30 assist in reducing the tendency of thechannel 22 of compressing or spreading add causing the edges of the mat3O to elevate above the surface upon which the mat is placed. Theelevation of the edges of the mat 10 above the surface upon which themat is placed increases the possibility of wear, can present animpediment to ingress and egress of a vehicle or dwelling and cancontribute to mat slippage during use. The rib members 30 are shown asspaced approximately one inch apart however, spacings from about 1/2 toabout 2 inches may be used.

As shown in FIGS. 7, 8, and 9, the floor mat 10 preferably includes aplurality of nib elements 32 and/or other anti-slippage anchoring meanssuch as the material 35 shown in FIG. 7. The nib elements illustrativelyand preferably are of frusto-conical shape and are connected to thelower surface of base layer 15. The nib elements 32 extend substantiallyvertically downward from the base layer 15 and when provided through thematerial 35 upon the bottom surface of the base layer 15. The material35 may be a tacky pressure-sensitive adhesive material as described inU.S. application Ser. No. 07/642,926 filed Jan. 18, 1991, orpolyurethane foam as described in U.S. application Ser. No. 07/687,234filed Apr. 18, 1991, the disclosures of which are incorporated herein byreference as if set out fully.

As shown in FIGS. 10 and 11, the main body section 20 of the floor mat10 can also have a channel 22a formed in a portion thereof, andpreferably opening from a bottom surface 19a of the main body sectionThe upper surface 23a of the portion of the main body section 20 havingthe channel 22a is disposed at an elevation above the elevation of theremainder of the main body section 20 and is substantially the sameelevation as the upper surface 23 of edge section Preferably, thiselevated upper surface 23a of the main body section 20 provides adecorative and aesthetically pleasing design in the main body section20, for example, the umbrella shown in FIGS. 10 and 11 or indicia of anautomobile manufacturer. While a raised portion in the main body of thefloor mat has been described, other methods of producing such indicia ordesign in the main body of the floor mat may be utilized. Examples ofother methods which could be used include, but is not limited to,embroidery or other stitching means, variations in color or texture ofthe face layer material or by impressing into the upper surface or facelayer the design or logo.

The method of the present invention includes contacting the upper or topsurface 17 of a base layer 15 to the bottom surface of the upper facelayer 12 followed by placing the base layer 15 and face layer 12 undercompressive molding pressure, (e.g., a pressure selected from the rangeof 50 psi to about 250 psi). Preferably, if a tufted pile tufted carpetis the upper face layer 12, the pile is crushed while the face layer 12and the base layer 15 are under the compressive molding pressure. Achannel 22 or channel 22a is molded in, and preferably opens from thebottom surface 19 of the base layer 15 or the bottom surface 19a of themain body portion 20 while the upper face layer 12 and base layer 15 areunder compressive molding pressure. A portion of the bottom surface ofthe face layer 12 becomes embedded in the base layer during heating andcuring of the base layer 15 at a temperature of from about 250° F. toabout 400° C. while the carpet and base layer are under the compressivemolding pressure. The face layer of the multilayered mat 10 is cooled toa temperature of less than 100° F. to maintain the fibers of the carpetyarns below a temperature at which the pile become substantiallypermanently deformed under the applied molding pressure and so as tomaintain the resiliency of the face layer 12 upon release of the moldingpressure. The cooling is conducted simultaneously while the face layer12 and base layer 15 are under pressure. The heating of the base layer15 is maintained until the elastomeric material or the thermoplasticmaterial of the base layer are cured. A suitable molding apparatus isdescribed more fully in U.S. Pat. No. 4,174,991, although other moldingtechniques, particularly if thermoplastic materials are used, will beapparent to one skilled in the art.

A sufficient compressive molding pressure must be employed in thepresent invention to achieve a bond between the bottom surface of theface layer 12 and the upper surface 17 of the base layer 15. Sufficientcompressive molding pressure is also required to mold the base layermaterial into the recess in the mold cavity. Thus, for example,sufficient molding pressure must be employed in order to embed the loopsof a tufted pile carpet face layer 12 into the base layer 15 and also toinsure that the elastomeric base layer 15 is formed into the desiredchannel 22. Furthermore, sufficient pressure may be required to causethe flow of the base layer material when forming the channel 22 and toform the relatively thick edge section 21 adjacent the periphery of thefloor mat 10.

It will be appreciated that a mat in accordance with the presentinvention can be used upon various flooring having carpeted areas orhard surface areas or both types of areas, such as in automobiles and inhouseholds. Additionally, the mat will have a longer useful life and canbe used more successfully under wet or dirty conditions than a mathaving only conventional anchoring means.

While a preferred embodiment of the invention has been shown anddescribed, this was for purposes of illustration only, and not forpurposes of limitation, the scope of the invention being in accordancewith the following claims.

That which is claimed is:
 1. A method of forming an integral raisedportion in an edge section of a floor mat; said floor mat having apliable multilayer structure having an upper .Iadd.carpet .Iaddend.facelayer overlying a base layer, and having a main body section bordered bysaid edge section;molding an integrally molded channel in the edgesection and extending longitudinally thereof by placing the base layerand the face layer under a compressive molding pressure applied to abottom surface of the base layer and the top surface of the .Iadd.carpet.Iaddend.face layer; embedding a portion of the bottom surface of the.Iadd.carpet .Iaddend.face layer in the upper surface of the base layer.Iadd.such that a pile of the carpet face layer has a substantiallyuniform height above the upper surface of the base layer across the mainbody section.Iaddend.; heating the base layer to cure the base layerwhile the face layer and the base layer are under the compressivemolding pressure; and maintaining the heating of the base layer untilthe base layer is cured, so as to form an integral raised portion in theedge section of the floor mat, defined by said integrally moldedchannel.Iadd.; wherein said embedding step further comprises embedding aportion of the bottom surface of the carpet face layer in the uppersurface of the base layer such that the pile of the carpet face layerhas a substantially uniform height above the upper surface of the baselayer across both the main body section and the edge section.Iaddend..2. A method according to claim 1 where the face layer is comprised oftufted pile carpeting, said process further comprising the step ofcrushing the carpet pile while the base layer and the face layer areunder compressive molding pressure.
 3. A method according to claim 1where the face layer is comprised of tufted pile carpeting, said processfurther comprising the step of cooling the face layer to maintain thepile carpeting of the face layer below a temperature at which the carpetpile becomes substantially permanently deformed under the appliedmolding pressure so as to maintain the resiliency of the carpet pileupon release of the compressive molding pressure, the cooling beingconducted simultaneously while the face layer and the base layer areunder pressure.
 4. A method according to claim 3 further comprising thestep of crushing the carpet pile carpeting while the base layer and theface layer are under compressive molding pressure.
 5. .[.A methodaccording to claim 1.]. .Iadd.A method of forming an integral raisedportion in an edge section of a floor mat; said floor mat having apliable multilayer structure having an upper carpet face layer overlyinga base layer, and having a main body section bordered by said edgesection;molding an integrally molded channel in the edge section andextending longitudinally thereof by placing the base layer and the facelayer under a compressive molding pressure applied to a bottom surfaceof the base layer and the top surface of the carpet face layer;embedding a portion of the bottom surface of the carpet face layer inthe upper surface of the base layer such that a pile of the carpet facelayer has a substantially uniform height above the upper surface of thebase layer across the main body section; heating the base layer to curethe base layer while the face layer and the base layer are under thecompressive molding pressure; and maintaining the heating of the baselayer until the base layer is cured, so as to form an integral raisedportion in the edge section of the floor mat, defined by said integrallymolded channel; .Iaddend. wherein said molding step further comprisesmolding rib members disposed within and extending transversely acrossthe channel.
 6. .[.A method according to claim 1.]. .Iadd.A method offorming an integral raised portion in an edge section of a floor mat;said floor mat having a pliable multilayer structure having an uppercarpet face layer overlying a base layer, and having a main body sectionbordered by said edge section;molding an integrally molded channel inthe edge section and extending longitudinally thereof by placing thebase layer and the face layer under a compressive molding pressureapplied to a bottom surface of the base layer and the top surface of thecarpet face layer; embedding a portion of the bottom surface of thecarpet face layer in the upper surface of the base layer such that apile of the carpet face layer has a substantially uniform height abovethe upper surface of the base layer across the main body section;heating the base layer to cure the base layer while the face layer andthe base layer are under the compressive molding pressure; andmaintaining the heating of the base layer until the base layer is cured,so as to form an integral raised portion in the edge section of thefloor mat, defined by said integrally molded channel; .Iaddend. whereinsaid molding step includes forming a relatively thin main body sectionbordered by a relatively thick edge section.
 7. A method according toclaim 1, where the base layer is formed of a heat curable elastomericmaterial.
 8. A method according to claim 7 wherein the heat curableelastomeric material is selected from the group consisting of naturalrubber, butadiene polymers, butadiene copolymers, isoprene polymers,isoprene copolymers, chloroprene rubbers, nitrile rubbers, butylrubbers, and ethylene-propylene rubbers and blends and copolymersthereof.
 9. A method according to claim 7 wherein the curableelastomeric material is styrene-butadiene rubber.
 10. A method offorming an integral raised portion is an edge section of a floor mat;said floor mat having a pliable multilayer structure having an upperface layer of tufted pile carpeting and overlying a base layer of a heatcurable elastomeric material and having a relatively thin main bodysection bordered by a relatively thick edge section; said edge sectionhaving an integrally molded channel extending longitudinally thereof andopening from the bottom surface thereof, and having an upper surfacedisposed at an elevation above the elevation of said main body sectionof said base layer so as to form an integral raised portion in said edgesection, said method comprising:contacting a top surface of the baselayer to a bottom surface of the face layer; placing the base layer andthe face layer under a compressive molding pressure selected from therange of about 50 psi to about 250 psi, where the compressive moldingpressure is applied to a bottom surface of the base layer and a topsurface of the face layer to mold a channel in and opening from the edgesection and extending longitudinally thereof while the base layer andthe face layer form a relatively thin main body section bordered by arelatively thick edge section; embedding a portion of the bottom surfaceof the face layer in the top surface of the base layer; heating the baselayer to a temperature within the range of about 250° F. to about 400°F. to cure the heat curable elastomeric material of the base layer whilethe face layer and the base layer are under the compressive moldingpressure; cooling the face layer to a temperature less than about 100°F. to maintain the pile carpeting of the face layer below a temperatureat which the carpet pile becomes substantially permanently deformedunder the applied molding pressure so as to maintain the resiliency ofthe carpet pile upon release of the compressive molding pressure, thecooling being conducted simultaneously while the face layer and the baselayer are under pressure; and maintaining the heating of the base layerfor a period of time selected from the range of about one minute toabout twenty minutes until the heat curable elastomeric material of thebase layer is cured, so as to form an integral raised portion in theedge section of the floor mat, defined by said integrity molded channel.11. A method according to claim 10, wherein said molding step includesmolding rib members disposed within and extending transversely acrossthe channel.
 12. A method according to claim 10 wherein the heat curableelastomeric material is styrene-butadiene rubber.
 13. A method offorming an integral raised portion in an edge section of a floor matwherein said floor mat has a pliable multilayer structure having anupper face layer overlying a base layer wherein said base layer has amain body section bordered by an edge section having an integrallymolded channel extending longitudinally thereof and a step portionextending outward from said edge section to the edge of said mat, saidmethod comprising:molding a step portion extending outward from the edgesection and an integrally molded channel in the edge section extendinglongitudinally thereof by placing the base layer and the face layerunder a compressive molding pressure applied to a bottom surface of thebase layer and the top surface of the face layer.Iadd., the step portionbeing configured such that, when the mat is in use, the bottom surfaceof the step portion is substantially coplanar with the bottom surface ofthe main body section.Iaddend.; embedding a portion of the bottomsurface of the face layer in the upper surface of the base layer;heating the base layer to cure the base layer while the face layer andthe base layer are under the compressive molding pressure; andmaintaining the heating of the base layer until the base layer is cured,so as to form an integral raised portion in the edge section of thefloor mat, defined by said integrally molded channel.
 14. A method offorming an integral raised portion in an edge section of a floor matwherein said floor mat has a pliable multilayer structure having anupper face layer overlying a base layer wherein said base layer has amain body section bordered by the edge section and wherein said edgesection has an integrally molded channel extending longitudinallythereof and having a plurality of rib members disposed therein andextending transversely across the channel, said methodcomprising:molding an integrally molded channel in the edge sectionextending longitudinally thereof and a plurality of rib members disposedwithin the channel and extending transversely across the channel, byplacing the base layer and the face layer under a compressive moldingpressure applied to a bottom surface of the base layer and the topsurface of the face layer; embedding a portion of the bottom surface ofthe face layer in the upper surface of the base layer; heating the baselayer to cure the base layer while the face layer and the base layer areunder the compressive molding pressure; and maintaining the heating ofthe base layer until the base layer is cured, so as to form an integralraised portion in the edge section of the floor mat, defined by saidintegrally molded channel. .Iadd.
 15. A method of forming an integralraised portion in a pliable, multi-layer floor mat having an upper facelayer overlying a base layer, said method comprising the stepsof:molding an integrally molded channel in the floor mat by placing thebase layer and the face layer under a compressive molding pressureapplied to a bottom surface of the base layer and the top surface of theface layer; embedding a portion of the bottom surface of the face layerin the upper surface of the base layer; heating the base layer to curethe base layer while the face layer and the base layer are under thecompressive molding pressure; and maintaining the heating of the baselayer until the base layer is cured, so as to form an integral raisedportion in the floor mat, defined by said integrally molded channel;wherein said molding step includes forming a relatively thin main bodysection bordered by a relatively thick edge section. .Iaddend..Iadd.16.A method according to claim 15 where the face layer is comprised oftufted pile carpeting, said process further comprising the step ofcrushing the carpet pile while the base layer and the face layer areunder compressive molding pressure. .Iaddend..Iadd.17. A methodaccording to claim 15 where the face layer is comprised of tufted pilecarpeting, said process further comprising the step of cooling the facelayer to maintain the pile carpeting of the face layer below atemperature at which the carpet pile becomes substantially permanentlydeformed under the applied molding pressure so as to maintain theresiliency of the carpet pile upon release of the compressive moldingpressure, the cooling being conducted simultaneously while the facelayer and the base layer are under pressure. .Iaddend..Iadd.18. A methodaccording to claim 17 comprising the step of crushing the carpet pilewhile the base layer and the face layer are under compressive moldingpressure. .Iaddend..Iadd.19. A method according to claim 15 wherein saidmolding step further comprises molding rib members disposed within andextending transversely across the channel. .Iaddend..Iadd.20. A methodaccording to claim 15 where the base layer is formed of a heat curableelastomeric material. .Iaddend..Iadd.21. A method according to claim 20wherein the heat curable elastomeric material is selected from the groupconsisting of natural rubber, butadiene polymers, butadiene copolymers,isoprene polymers, isoprene copolymers, chloroprene rubbers, nitrilerubbers, butyl rubbers, and ethylene-propylene rubbers and blends andcopolymers thereof. .Iaddend..Iadd.22. A method according to claim 20wherein the curable elastomeric material is styrene-butadiene rubber..Iaddend..Iadd.23. An automobile floor mat comprising:a pliablemultilayer structure having an upper face layer of carpeting overlyingand embedded in a base layer wherein said base layer has a relativelythin main body section bordered by a relatively thick edge section withsaid upper face layer being coextensive with at least said edge sectionof said base layer; said edge section having a molded channel extendinglongitudinally thereof and opening from the bottom surface of said edgesection, having an upper surface disposed at an elevation above theelevation of said main body section of said base layer, and providing adecorative edge portion in said upper face layer; and a plurality of ribmembers integrally molded with, disposed within and extendingtransversely across said channel. .Iaddend..Iadd.24. An automobile floormat according to claim 23 wherein each said rib member extends acrossonly a portion of the depth of said channel. .Iaddend..Iadd.5. Anautomobile floor mat according to claim 23 further comprising a stepportion of said pliable multilayer structure extending outward from saidedge section to the edge of said mat. .Iaddend..Iadd.26. An automobilefloor mat according to claim 25 configured such that, when said mat isin use, the bottom surface of said step portion is substantiallycoplanar with the bottom surface of the main body section..Iaddend..Iadd.27. An automobile floor mat according to claim 23 whereinsaid main body section of said base layer is of sufficient thickness toallow formation of a bottom surface of said main body section of saidbase layer which differs substantially from the shape of the bottomsurface of the main body section of the upper face layer..Iaddend..Iadd.28. An automobile floor mat according to claim 27 furthercomprising anchoring means including a plurality of elongate nibelements connected to and projecting downwardly from the bottom surfaceof said main body section of said base layer. .Iaddend..Iadd.29. Anautomobile floor mat comprising:a pliable multilayer structure having anupper face layer of carpeting overlying a base layer wherein said baselayer has a relatively thin main body section bordered by a relativelythick edge section and a step portion integrally molded with andextending outward from said edge section to the edge of said mat, saidedge section having a channel extending longitudinally thereof andopening from the bottom surface of said edge section and having an uppersurface disposed at an elevation above the elevation of said main bodysection of said base layer and providing a decorative edge portion insaid upper face layer. .Iaddend..Iadd.30. An automobile floor mataccording to claim 29 where, when said mat is in use, the bottom surfaceof said step portion is substantially coplanar with the bottom surfaceof the main body section. .Iaddend..Iadd.31. An automobile floor mataccording to claim 29 wherein said main body section of said base layeris of sufficient thickness to allow formation of a bottom surface ofsaid main body section of said base layer which differs substantiallyfrom the shape of the bottom surface of the main body section of theupper face layer. .Iaddend..Iadd.32. An automobile floor mat accordingto claim 31 further comprising anchoring means including a plurality ofelongate nib elements connected to and projecting downwardly from thebottom surface of said main body section of said base layer..Iaddend..Iadd.33. A method of forming an integral raised portion in anedge section of a floor mat; said floor mat having a pliable multilayerstructure having an upper face layer overlying a base layer, and havinga main body section bordered by said edge section;molding an integrallymolded channel in the edge section and extending longitudinally thereofby placing the base layer and the face layer under a compressive moldingpressure applied to a bottom surface of the base layer and the topsurface of the face layer, wherein said molding step includes forming arelatively thin main body section bordered by a relatively thick edgesection; embedding a portion of the bottom surface of the face layer inthe upper surface of the base layer; heating the base layer to cure thebase layer while the face layer and the base layer are under thecompressive molding pressure; and maintaining the heating of the baselayer until the base layer is cured, so as to form an integral raisedportion in the edge section of the floor mat, defined by said integrallymolded channel. .Iaddend.